| Removal and Installation Special Tool(s) | | Socket, Fuel Injector (22 mm) 310-063 (23-050) | Materials Name Specification Grease SA-M1C9107-A Removal All vehicles | | -
Remove the heated oxygen sensor (HO2S).
For additional information, refer to: Heated Oxygen Sensor (HO2S) (303-14 Electronic Engine Controls - 1.3L Duratec-8V (Rocam)/1.6L Duratec-8V (Rocam), Removal and Installation).
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Remove and discard the catalytic converter upper retaining nuts in the sequence shown. | | | -
Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting) Jacking (Description and Operation), Lifting (Description and Operation). | | | -
CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure. Support the exhaust flexible pipe with a support wrap or splint. | Vehicles with two-piece catalytic converter and exhaust flexible pipe | | -
Disconnect the exhaust flexible pipe from the catalytic converter. - Discard the exhaust flexible pipe to catalytic converter clamp retaining nut.
| Vehicles with one-piece catalytic converter and exhaust flexible pipe | | -
CAUTION:Twisting the exhaust flexible pipe more than two degrees may cause damage resulting in failure. NOTE:Use a pry-bar to prevent the exhaust flexible pipe from twisting when removing the catalytic converter to muffler and tailpipe assembly retaining nuts. Disconnect the catalytic converter from the muffler and tailpipe assembly. - Remove and discard the catalytic converter to muffler and tailpipe assembly gasket and retaining nuts.
| All vehicles | | -
Disconnect the catalyst monitor sensor electrical connector. | | | -
Using the special tool, remove the catalyst monitor sensor. | | | -
Remove the catalytic converter heat shield. | | | -
Remove the catalytic converter. - Remove and discard the exhaust manifold gasket.
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NOTE:This step is only necessary if installing a new catalytic converter. Remove the catalytic converter mounting bracket. | Installation All vehicles | | -
NOTE:This step is only necessary if installing a new catalytic converter. Install the catalytic converter mounting bracket. | | | -
CAUTION:Never use jointing compound forward of the catalytic converter. NOTE:Do not fully tighten the catalytic converter lower retaining bolts at this stage. Install the catalytic converter. | | | -
NOTE:Coat the exhaust manifold studs with grease. NOTE:Install a new exhaust manifold gasket and new catalytic converter retaining nuts. Tighten the catalytic converter retaining nuts in the sequence shown. | | | -
Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting) Jacking (Description and Operation), Lifting (Description and Operation). | | | -
Tighten the catalytic converter lower retaining bolts. | | | -
Using the special tool, install the catalyst monitor sensor. | | | -
CAUTION:Make sure that the catalyst monitor sensor electrical cable is routed and secured in a way that it cannot be damaged by heat or moving components. Connect the catalyst monitor sensor electrical connector. | | | -
Install the catalytic converter heat shield. | Vehicles with two-piece catalytic converter and exhaust flexible pipe | | -
Connect the exhaust flexible pipe to the catalytic converter. | Vehicles with one-piece catalytic converter and exhaust flexible pipe | | -
CAUTION:Twisting the exhaust flexible pipe more than two degrees may cause damage resulting in failure. NOTE:Use a pry-bar to prevent the exhaust flexible pipe from twisting when installing the catalytic converter to muffler and tailpipe assembly retaining nuts. NOTE:Coat the catalytic converter to muffler and tailpipe assembly studs with grease. NOTE:Install a new catalytic converter to muffler and tailpipe assembly gasket and retaining nuts. Connect the catalytic converter to the muffler and tailpipe assembly. | All vehicles | | -
Remove the exhaust flexible pipe support wrap or splint. | | | -
Install the HO2S.
For additional information, refer to: Heated Oxygen Sensor (HO2S) (303-14 Electronic Engine Controls - 1.3L Duratec-8V (Rocam)/1.6L Duratec-8V (Rocam), Removal and Installation).
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